Mesh Abrasive Cloth

ABSTRACT

The invention is a new napped mesh abrasive cloth that is made with a gray cloth that is a napped fabric. It is used in the coated abrasives industry. Its uniqueness is in the construction. It is formed by a base material, an abrasive layer and a multilayer adhesive. On the bottom surface of the material there is nap, on the top surface of base material, there is an abrasive layer that is attached by a layer of primer. Finally, the surface of the abrasive layer is then coated with a multilayer adhesive.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the priority of Chinese Patent Application No.201320163684.8, filed Apr. 3, 2013, which is incorporated herein byreference.

FIELD OF THE INVENTION

The invention is of a new napped mesh abrasive cloth that is used in thecoated abrasives industry.

BACKGROUND OF THE INVENTION

There are many forms that traditional abrasive paper and abrasive clothcome in, such as discs, belts, and sheets. All the abrasives productsused right now are comprised of a separate flannel backing that isattached to the abrasive paper or cloth, and then attached to thesanding tool to perform its sanding functions. This sanding method is acomplicated process. Even if you directly plant the abrasives onto theflannel, it might be adhesive, but clogging becomes a severe problem.There is a type of abrasive product on the market right now that is of amesh construction with an attached Velcro backing, but the grinding areais reduced and the manufacturing process is complicated with additionalprocedures.

BRIEF DESCRIPTION OF THE INVENTION

The objective of the invention is to overcome the inadequacies of thecurrent technology to provide users with a new anti-clogging napped meshabrasive cloth that improves dust removal capacity and increases thesanding surface area.

The new technological solutions are developed to combat theabovementioned problems: to use a napped mesh abrasive cloth that iscomprised of a base material, an abrasive layer, a multilayer adhesivewith anti-clogging or anti-static coating. On the top bottom surface ofthe base material there is nap, on the top surface of the base materialis an abrasive layer attached by a layer of primer, and the surface ofthe abrasive layer is a multilayer adhesive and an anti-clogging oranti-static coating.

The material for the base material is a nap cloth that can be chosenfrom a group consisting of cotton cloth, polyester cloth, acrylic cloth,polypropylene cloth, bonding cloth or linen cloth.

The fabric preferably has loops on the surface.

The shape of the mesh construction can be one or a combination ofcircular, elliptical, polygonal and irregular shapes.

The product works best if there are vents around the cutouts. Vents areeven smaller shapes of cutouts on the mesh that can be circular,elliptical, polygonal or irregular shapes. Even though the vents do notallow dust to pass, it can balance the internal and external pressure ofthe abrasive cloth, making debris easier to remove which leads to lessclogging.

The multilayer adhesive has an anti-clogging or anti-static coating.

A single or multi-layer of abrasives can form the abrasive layer. Themethod used can be electrostatic abrasives planting or gravity sandplanting.

The adhesive binders of the layer of primer and the multilayer adhesivecan be made from aphenolic resins, epoxy resins, urea-formaldehyde,polyvinyl alcohols, latexes or a combination thereof.

The abrasives used to produce the abrasive layer can be selected fromaluminum oxide, silicon carbide, calcined alumina, semi brittle alumina,diamond, ceramic-abrasive or a combination thereof.

Roller raising machines can be used to create the nap on the fabric orthe loops can be created during the weaving process. The nap is onlypresent around the mesh cut-outs.

Compared to current technology, the benefits of the new invention of thenapped mesh abrasive cloth are the following: the product adopts thenapped mesh fabric as the grey cloth for the backing which already hasnap and fabric loops to enable direct attachment to sanding tools, thuseliminating a separate attachment to Velcro. The new napped meshabrasive cloth does not require the process of compressing a new naplayer on top of the base material; instead, adhesives can be directlyplanted onto the base material. The end product can be directly fastenedto sanding tools, thus reducing the manufacturing process and cost. Atthe same time, the mesh construction of the product has a greateranti-clogging effect that greatly improves sanding efficiency andproduct lifetime.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 shows the structure diagram of a napped mesh abrasive clothaccording to an embodiment.

FIG. 2 shows the positive schematic diagram of a napped mesh abrasivecloth according to an embodiment.

WHEREIN IN THE FIGURES:

-   -   1: Base material    -   2: Abrasive Layer    -   3: Multilayer Adhesive    -   4: Nap    -   5: Mesh

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

FIGS. 1 and 2 show the preferred embodiment of a napped mesh abrasivecloth. The disclosure may be more completely understood in considerationof the following detailed description of various embodiments of thedisclosure.

Refer to FIGS. 1 and 2, the napped mesh abrasive cloth is comprised of abase material (1), an abrasive layer (2), and a multilayer adhesive (3).The bottom of the fabric has a nap (4), and a mesh construction is used.On the top of the base material, there is a layer of phenolic resinprimer that adheres the layer of aluminum oxide abrasives to the fabric.The multilayer adhesive on top of the abrasive layer is of phenolicresin also. The side of the product with nap can be directly attached tothe sanding tools, making the process more convenient.

Small vents are formed around the mesh (5) cut-outs.

The abrasive layer (2) can be formed by a single layer of abrasiveplanting.

The abrasive planting process takes place after the napped fabric thatis the base material has been chemically treated, chemically coated orphysically polished.

The multilayer adhesive has an anti-static coating, anti-cloggingcoating or a combination of both. The anti-static coating can be madefrom hot rubber cement; the anti-clogging coating can be made fromstearic acid salt.

The adhesive binders in the primer and multilayer adhesive is made fromapheolic resins, epoxy resins, urea-formadehydes, polyvinyl alcohols,latexes, or a combination thereof.

The naps or loops of the backing, are formed either by roller raisingmachine or during weaving, which around the meshes.

The abrasive layer is made from one of the following materials: aluminumoxide, silicon carbide, calcined alumina, diamond, ceramic abrasives.

All the nap on the fabric is formed by the roller raising machine, onlythe area surrounding the mesh has nap, the mesh cut-outs do not havenap.

The base material is a nap fabric. It can be chosen from the followingfabrics: cotton cloth, polyester cloth, acrylic cloth, polypropylenecloth, bonding cloth, linen cloth.

Specific Manufacturing Process

Exemplary Process 1: Using the napped mesh fabric as illustrated in FIG.2, with the mesh cut out in a diamond shape, the gray cloth is made intothe base material after it is sprayed with adhesives. The layer ofprimer is then applied that includes resin adhesive binders, fillers andadditives. The aluminum oxide is then planted and finished withmultilayer adhesive that also includes resin adhesives binders, fillers,and additives and laid out to dry. The finished product is cut into discshapes and used directly on the sanding tools to provide great sandingpower and anti-clogging abilities.

Exemplary Process 2: The base material is obtained by treating thenapped mesh fabric with circular mesh cutouts with special rollercoating technology. A primer is applied that includes resin adhesivesbinders, fillers and additives, then the abrasive is planted and a finallayer of adhesives that includes resin adhesive binders, fillers andadditives is applied. The final product can be cut into disc shapes.

Exemplary Process 3: A fabric with looped surface is chosen as the basematerial and treated with a special roller coating technology. A primeris applied that includes resin adhesive binders, fillers and additives,then the abrasive is planted and a final layer of adhesives thatincludes resin adhesive binders, fillers and additives is applied. Thefinal product can be cut into disc shapes.

The above describes exemplary embodiments of the invention, and not alimitation of the use of this invention or similar products. Any personhaving ordinary skill in the art can take on various modifications andalterations without departing from the spirit and scope of thedisclosure. Accordingly, it is to be understood that the embodiments ofthe present disclosure to be controlled by the limitations set forth inthe claims and any equivalents thereof.

1. A napped mesh abrasive fabric, comprising: a base material with mesh,bottom surface of the base material being nap; an abrasive layer on topof the base material attached by a coating of primer; and multilayeradhesive on top of the abrasive layer.
 2. The napped mesh abrasivefabric of claim 1, wherein the base material is a napped mesh fabric. 3.The napped mesh abrasive fabric of claim 1, wherein the base material isat least one of: cotton, polyester, acrylic, polyproylene, bonding orlinen fabrics.
 4. The napped mesh abrasive fabric of claim 1, whereinthe base material includes a fabric with loops on the surface.
 5. Thenapped mesh abrasive fabric of claim 1, wherein the mesh of the basematerial comprises separate small vents.
 6. The napped mesh abrasivefabric of claim 1, wherein the shape of the mesh is one of circular,ellipse, polygonal, or irregular shape.
 7. The napped mesh abrasivefabric of claim 1, wherein the multilayer adhesive comprises ananti-static coating, an anti-block coating, or both.
 8. The napped meshabrasive fabric of claim 1, wherein the abrasive layer is formed by asingle-layer abrasive planting or the multilayer abrasive planting.